Electromagnetic actuator



July 5, 1960 J. w. MOBARRY 2,944,193

ELECTROMAGNETICACTUATOR Filed April 28, 1958 I I INVEN TOR. 33 47 5o 45 JOHN W. MOBARRY BY f 6 ATTORNEY United States Patent 2,944,195 ELECTROMAGNETIC ACTUATOR John W. Mobarry, Edina, Minn., assignor to Minneapolis- Honeywell Regulator Company, Minneapolis, Minn, a corporation of Delaware Filed Apr. 28, 1958, Ser. No. 731,290 12 Claims. (Cl. 317-184) The present invention is directed to an electromagnetic type of actuator, such an actuator particularly adapted for operating electrical contacts. This type, of device is more'commonly referred to as a contactor or relay.

The contactor or relay art is a highly developed art and has been actively progressing for well over fifty years. Since this art is so highly developed, a struggle is constantly being made to reduce thecost of the contactors and relays being marketed in all of the electrical control fields. In recent years air conditioning systems and their associated electrically operated equipment have become quite common. Air conditioning systems utilizing electrical drive equipment require substantial amounts of power and have. become highly competitive. In order to compete in the control system art or" the types used in the air conditioning field, it has been necessary to continuously provide better and less expensive types of contactors and relays. In this competitive struggle there is also-the constant effort to provide control units which are physically small in size as well as inexpensive to manufacture. All of the cost reductions and reductions in physical size must be accomplished without a loss of electrical efiiciency and the units must meet existing safety standards.

In order to continuously meet the demands of this highly complex art it has been necessary to reduce the number of parts and the complexity of parts being used to fabricate contactors and relays. This reduction in the number and complexity of parts must also be accompanied by a reduction in cost as far as assembly of the units is concerned. It becomes obvious as parts become smaller in size that there would normally be a tendency to increase assembly labor since the smaller parts would be harder to handle. The presently disclosed contactor or relay overcomes many of the diificulties previously encountered in the art and provides a highly eflicient, low cost, and physically small device.

Generally, the object of the present contactor or relay is to produce a device which is physically small but is yet easily assembled since some of its partsprovide a dual function.

A more specific object of the present invention is to disclose a contactor or relay having a frame made of an electrically conductive material, wherein, the frame is utilized in forming integral shading rings which in turn hold the energizing coil in place on the device.

Yet another object of the present invention is to disclose a unit having a magnetic structure formed substantially of solid magnetic material instead of the more costly laminated magnetic materials used in similar devices.

Still another object of the present device is to provide a magnetic actuator capable of opera-ting other devices in addition toelectrical contacts.

A further object of the present invention is todisand more specifically is directed to.

close a magnetic actuator which is exceedingly compact and efiicient, both mechanically and electrically.

These and other objects will become apparent when this specification and the single sheet of drawings is con sidered, wherein:

Figure 1 is a cross-section of an electrical contactor or relay, and discloses both the magnetic circuit and the electrical contact structure; 7

Figure 2 is a cross-section of Figure 1 along lines 22 showing the integral shading rings of the electrical framework holding the'energizing coil into the device, and;

Figure 3 is a cross-section of part of Figure 1 along lines 3-3 disclosing an elevation of the magnetic actuator section of the device.

In the cross-section disclosed in Figure 1, a contact structure is generally shown at 10. The contact structure includes terminals 11 and 12 which are electrically connected to a pair of contacts 13 and 14. It will be appreciated that the cross-section of the contact structure 10 shows only one-half of the terminals and contacts and that a second pair of terminals and contacts lie in the same plane as those disclosed. In effect, the undisclosed parts are reflected images of those disclosed, and this type of an arrangement is well known in the relay art.

Cooperating with contacts 13 and 14 are two shorting bars 15 and 16. The shorting bars 15 and 16 are perpendicular to the plane of the paper or drawing and include four contacts, of which only numbers 20 and 21 are shown. The other two contacts cooperate with the image section of that disclosed and act as a shorting bar so that a circuit can be completed between each pair of contacts; Each of the shorting bars 15 and 16 are held in place by springs 22 and clips 23 which are attached to the upper end of the armature means or guide 24. It will be appreciated that the shorting bars 15 and 16 are dropped into slots in the armature means 24 and that the springs 22 are then inserted to hold them in place. The spring clips 23 then lock the entire structure into the biased arrangement so that the shorting bars are free to move in an upward direction when the device is operated.

The armature means or guide 24' passes through a pair of slots 25 and 26 which form a guideway so that the guide or armature means 24 can move substantially in an up-down direction only. The slots 25 and 26 are separated by an insulating guide 27 to help retain the armature means 24 in a vertical position. The passageways 25 and 26 are large enough so that the guide 24 is free to move without binding and has a slight amount of horizontal play.

The contact structure 10 which has been disclosed, can be replaced by most any type of contact arrangement that is convenient. This contact arrangement requires only that an insulating support be provided which is substantially horizontal in nature and which has a passage through it so that the armature 24 is free to move in an up and down direction to operate the contact arrangement.

Two frame members 30 and 31 are provided and are made from an electrically conductive material such as brass or aluminum. The brackets 30 and 31 are substantially identical in construction. Each of the brackets 3.0 and 31 has a mounting foot '32 and 33 which can be of any convenient shape and which further have mounting holes 34 and 35 so that the unit can be conveniently mounted in a control panel or on any associated equipment. The brackets 30 and 31 further have upstanding support members 36, 37, 38 and 39. These four upstanding members provide the support to hold the switch or contact means 10 in place. It will be appreciated that with the four upstanding members 36 through 39 that any type of mounting means may be used to hold the insulated sections of the switch means The lower end of the brackets 36 through 39 have projections, two of which are shown at 4t) and 41. The projections 46 and 41 pass through slots (not shown) in a U-shaped magnetic member 42. The U-shaped magnetic member 42 is formed of a solid piece of magnetic steel and has the upstanding members or legs 43 and 44 while having the base member 45. The base member 45 is the portion which has the previously referred to slots that provide the mounting means for the projections 40 and 41 of the brackets 30 and 31.

A center laminated leg 46 is provided and has a projection 47 passing through a hole 50 in the bottom 45 of the U-shaped magnetic member 42. The laminations that make up the leg 46 are held together by a rivet 51 passing through the center line of the leg. The rivet 51 holds the laminations into the unitary leg 46 and the projection 47 is chisel-staked at 52 to spread the projection 47 and thereby lock the leg 46 into position. The magnetic member 42 along with the leg 46 forms an E- shaped magnetic core which has a center laminated leg and two outer upstanding portions 43 and 44 which are not laminated. The ends 53 and 54 of the upstanding portions 43 and 44 and the end 55 of the laminated leg 46 form a substantially flat plane which is perpendicular to the drawing in Figure l. Placed below this plane and around the leg 46 is an energizing coil 56 of any convenient construction. The coil 56 has connection leads 57 so that the coil 56 may be energized by any convenient external electrical source. The coil 56 can be constructed in any convenient manner and the only requirements are that it fit around the leg 46 but remains within the dimensions defined by the upstanding legs 43 and 44. The coil further must be short enough in height so that it remains below the plane established by the faces 53 to 55 of the upstanding members.

In order to hold the coil 56 in place two shading rings 60 and 61 are provided. The shading rings 60 and 61 lock the coil 56 against the bottom 45 of the magnetic structure 42 and hold it tightly in place. The shading rings 60 and 61 are further formed as an integral part of the brackets 80 and 31. This is accomplished by providing the Shading rings with connecting portions 62, 63, 64 and 65. The integral shading ring is formed by properly making a loop out of a section of the brackets 30' and 31 and then folding these loops over so as to be properly spaced in slots 66, 67, 68 and 69 which are formed into the ends 53 and 54 of the upstanding portions 43 and 44. It will be appreciated that since the brackets 30 and 31 are made of an electrically conductive material that the shading rings 60 and 61 perform their normal functions as shading rings while remaining an integral part of the brackets 30 and 31. The brackets 30 and 31 thus provide a plurality of functions such as providing the shading rings, a means of holding the device together in general, and a means of locking the energizing coil 56 into its proper position.

Associated with the brackets 30 and 31 are two U- shaped spring mounts 70 and 71. These U-shaped mounts slide over the brackets 30 and 31 and lock perpendicular thereto. Each of the U-shaped members 70 and 71 has a rounded end 72 and 73 to provide a stem on to which is placed the springs 74 and 75. The springs or resilient bias means: 74 and 75 have at their upper end a plate 76 which has depressions or dimples 80 and 81. The springs 74 and 75 ride around the dimples Bil and 81 and thereby the springs are held substantially in alignment with the rounded ends '72 and 73 of the brackets 7 i and 71. It will be appreciated that since the springs 74 and 75 are compression springs, that the springs tend to hold the plate 76 above the plane defined by the ends 53, 54 and 55 of the magnetic structure. The plate 76 passes around the armature means or guide 24 and has four tabs 82 which are bent around a substantially flat magnetic armature 84 so as to hold the armature 84 against the guide 24. The armature 84 is formed of a flat rectangular piece of solid magnetic material and it lies in a plane parallel to the plane defined by the ends 53, 54 and 55 of the upstanding members of the lower magnetic structure. With the arrangement disclosed the armature means 24 moves in a downward direction to operate the switch means 10 and the armature 84 moves parallel to the plane defined by the ends of the members 53, 54 and 55. As the armature moves downward it compresses the springs 74 and 65 until the armature 84 comes to rest against the lower magnetic structure. As soon as the coil 56 is deenergized, the springs 74 and 75 force the armature 84 into its upward position, as shown in Figure 1.

In considering the present device certain of its salient features must be kept clearly in mind. The present contactor or relay is constructed utilizing a highly simplified magnetic structure. This structure is defined by the substanti-ally flat, solid, magnetic armature 34 operating against an E-shaped magnetic structure having 'a great portion thereof formed of'asimilar solid magnetic material. This section more specifically is that formed of the U-shaped member 42. The only laminated section of the present electromagnetic device is the center leg 46. It will be appreciated that this type of a magnetic device can be fabricated with great ease and is considerably cheaperthan a magnetic structure of a more conventional laminated design. In addition to the advantages in the magnetic sections of the device, it becomes obvious that the bracket members 30 and 31 provide a plurality of functions and thereby accomplish a substantial cost reduction. These brackets '34 and 31 not only support the switch section or means 15 but further provide the support for the springs 74 and 75 along with the integral shading rings 60 and 61. Further, the integral shading rings 60 and 61 lock the coil 56 into its proper position thereby eliminating other mounting means. As thisunit is assembled, many functions are accomplished by a single part, and it is therefore considerably cheaper and faster to build the present relay or contactor than more conventional designs. The cost reductions accomplished by the construction of the present contactor or relay as well as the dual functions served by many of the parts is believed to exemplify the present invention. The disclosure specifically describes one form that the novel device may take, but the principles developed can be applied to many physical configurations and devices. Since this is true, the inventor wishes to be limited in the scope of this invention solely by the scope of the appended claims.

I claim as my invention:

1. An electromagnetic actuator particularly adapted to operate switch means mounted thereon: an E-shaped core formed of a solid U-shaped magnetic member and a laminated magnetic center leg member; said members defining a flat plane; an energizing coil surrounding said center leg and positioned below said plane; two frame members formed of an electrically conductive non-magnetic material and supported from said core; said frame members each having an integral shading ring linking opposite sides of said U-shaped member; said shading. rings further holding said coil against said core; each said frame member including two upstanding members supporting an insulated support substantially parallel to said plane; said insulated support having an opening therein as a guideway; a substantially fiat armature of solid-magnetic material parallel to said plane and attached to a guide passing through said guideway; and a pair of springs supported between said frame members and said guide to allow said flat magnetic armature to move parallel to said plane and operate said guide in said guideway.

2. An electromagnetic actuator particularly adapted to operate switch means mounted thereon: an E-shaped" core formed of a solid U-shaped magnetic member and defining a flat plane; an energizing coil surrounding said center leg and positioned below said plane; frame means formed of an electrically conductive non-magnetic material and supported from said core; said frame means having a plurality of integral shading rings linking parts of said U-shaped member; said shading rings further holding said coil against said core; said frame means including upstanding members supporting an insulated support substantially parallel to said plane; said insulated support having an opening therein as a guideway; armature means including a substantially flat, solid magnetic member parallel to said plane and attached to a guide passing through said guideway; and resilient bias means supported between said frame means and said armature means to allow said flat magnetic member to move parallel to said plane and operate said guide in said guideway.

3. An electromagnetic actuator: an E-shaped core formed of a solid U-shaped magnetic member and a laminated magnetic leg member; said members defining a fiat plane; a coil surrounding said leg and positioned below said plane; frame means formed of an electrically conductive material and supported adjacent to said coil; said frame means having integral shading ring means linking said U-shaped member; said shading ring means further holding said coil against said core; said frame means including upstanding members supporting an insulated support substantially parallel to said plane; said insulated support including guide means; armature means including a substantially fiat magnetic member held parallel to said plane by said guide means; and resilient bias means supported between said frame means and said armature means to allow said fiat magnetic member to move parallel to said plane.

4. An electromagnetic actuator: an E-shaped core formed of a solid U-shaped magnetic member and a laminated magnetic leg member; said members defining a plane; coil means surrounding said leg and positioned below said plane; frame means formed of an electrically conductive material and supported adjacent to said coil means; said frame means having integral shading ring means linking said U-shaped member; armature means including a substantially flat magnetic member held parallel to said plane; and resilient means supported between said frame means and said armature means to allow said flat magnetic member to move parallel to said plane.

5. An electromagnetic actuator particularly adapted to operate switch means mounted thereon: an E-shaped core formed of a solid U-shaped magnetic member and a laminated magnetic center leg member; said members defining a fiat plane; a coil surrounding said center leg and positioned below said plane; two frames supported on said core; said frames including upstanding members supporting an insulated support substantially parallel to said plane; said insulated support having an opening therein as a guideway, a solid armature of substantially flat magnetic material held parallel to said plane and attached to a guide means passing through said guideway; and two springs supported between said frames and said guide means to allow said armature to move parallel to said plane and operate said guide means in said guideway.

6. An electromagnetic actuator: an E-shaped core formed of a solid U-shaped magnetic member and a laminated magnetic leg member; said members defining a flat plane; coil means surrounding said leg and positioned below said plane; frame means supported adjacent to said coil means; said frame means including upstanding members supporting an insulated support substantially parallel to said plane; said insulated support having an opening therein as a guideway; armature means including a substantially flat, solid magnetic member parallel to said plane and attached to a guide passing through said guideway; and spring means supported between said frame means and said armature means to allow said flat magnetic member to move parallel to said plane and operate said guide in said guideway.

7. An electromagnetic actuator: an E-shaped core formed of a solid U-shaped magnetic member and a laminated magnetic leg member; said'members defining a plane; coil means positioned on said core out of line of said plane; frame means supported adjacent to said coil means; said frame means including upstanding members supporting an insulated support substantially parallel to said plane; armature means including a substantially flat magnetic member parallel to said plane and attached to guide mean-s; and resilient means supported between said frame means and said armature means to allow said flat magnetic member to move parallel to said plane and operate said guide means.

8. An electromagnetic actuator particularly adapted to operate switch means mounted thereon: an E-shaped core; said core defining a fiat plane; a coil positioned on the center leg of the core out of line of said plane; two frames formed of an electrically conductive material and supported adjacent to said coil; said frames each having an integral shading ring linking one outer leg of said core; said shading rings further holding said coil tight in said core; said frames including upstanding members supporting an insulated support substantially parallel to said plane; said insulated support including guide means; armature means including a magnetic member held parallel to said plane by said guide means; and springs supported between said frames and said armature means to allow said magnetic member to move parallel to said plane and operate said armture means in said guide means.

9. An electromagnetic actuator particularly adapted to operate switch means mounted thereon: an E-shaped magnetic core; said core defining a fiat plane; a coil positioned on said core out of line of said plane; frame means formed of an electrically conductive material and supported adjacent to said coil; said frame means having a plurality of integral shading rings linking the outer legs of said core; said frame means including upstanding members supporting an insulated support substantially parallel to said plane; said insulated support including guide means; armature means including a magnetic member held parallel to said plane; and spring means supported between said frame means and said armature means to allow said magnetic member to move parallel to said plane.

10. An electromagnetic actuator: a magnetic core having two relatively movable magnetic members; a first said member having a plurality of legs defining a flat plane; coil means positioned on said first member out of line of said plane; frame means formed of an electrically conductive material and supported adjacent to said coil means; said frame means having integral shading ring means linking said first magnetic member; said shading ring means further holding said coil tight in said cor'e; said frame means including upstanding members supporting an insulated support substantially parallel to said plane; said insulated support including guide means; armature means including a second said magnetic member held parallel to said plane by said guide means; and resilient bias means supported between said frame means and said armature means to allow said second magnetic member to move parallel to said plane and operate said armature means in said guide means.

11. An electromagnetic actuator: a magnetic core having two relatively movable magnetic members; a first said member having a plurality of legs defining a plane; coil means positioned on said member out of line of said plane; frame means formed of an electrically conductive material and supported adjacent to said coil means; said frame means having integral shading ring means linking said first magnetic member; said frame means including upstanding members supporting said insulated support; said insulated support including guide means; armature 7 means including a second said magnetic member held parand to said plane by said guide means; and resilient means supported between said frame means and saidarmature means to allow said second magnetic member to move parallel to said plane;

1 2. An electromagnetic actuator: an E-shaped core formed of a solid U-shaped' magnetic member and a laminatedmagnetic leg member;v coil means supported on: said core; frame means supported adjacent to said coil means; said frame means including upstanding members supporting an insulated support; armature means including a magnetic member attached to a guide means;

and resilient means supported between said frame means and said armature means to allow said armature means to move perpendicular to said E-s'haped core and thereny operate said guide means. 1

References Cited in the file of this patent UNITEDSTATES PATENTS 2,513,695 Van Valkenburg July 4, 195 -0 FOREIGN PATENTS 511,243 Germany Oct. 28, 1930* 

